Micro LED Display Module and Manufacturing Method Thereof

ABSTRACT

A micro LED display module and a manufacturing method thereof are provided. The micro LED display module comprises a driver chip block, a LED block, a circuit board and a color layer. The driver chip block has a plurality of pixel electrodes. The LED block is disposed in the driver chip block and has two semiconductor layers and a plurality of trenches. One of the two semiconductor layers is electrically connected to the pixel electrodes and the other is electrically connected to the light transmissive conductive layer. The trenches define a plurality of micro LED pixels arranged in an array. Each trench at least penetrates through the light emitting layer and one of the semiconductor layers. Each micro LED pixel corresponds to one of the pixel electrodes. The circuit board is electrically connected to the driver chip block, the color layer is disposed in the light transmissive conductive layer, and one of the semiconductor layers has a common electrode.

This application claims priority to Taiwan Patent Application No.106119260 filed on Jun. 9, 2017, which is allowed on Apr. 23, 2018 andwill be issued as Taiwan Patent in 2018.

CROSS-REFERENCES TO RELATED APPLICATIONS

Not applicable.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a light emitting diode (LED), andparticularly, to a micro LED display module and a manufacturing methodthereof.

Descriptions of the Related Art

Conventional light emitting diodes (LEDs) are mostly used as backlightsof liquid crystal displays (LCDs) or directly as light emitting pixelpoints of the LEDs. However, when being used directly as light emittingpixel points of the LEDs, the conventional LEDs are mostly used forlarge-sized advertisement panels but seldom used in consumer electronicproducts due to the low resolution thereof.

As a kind of new display technology, micro LEDs have been developed inrecent years. The micro LEDs are accomplished by miniaturizing andthinning LEDs into the micrometer scale and arraying them. In additionto having the advantages of the conventional inorganic LEDs such as highcolor saturation, high efficiency, high brightness and fast responseand, when being used in a display device, being capable of displayingthrough self-emission without the need of a backlight, the micro LEDsalso have the advantages of power saving, and simple in structure, thinand lightweight, and more importantly, the micro LEDs further have asuper high resolution.

Besides, as compared with the organic LEDs, colors of the micro LEDs areeasy to be accurately adjusted, and furthermore, the micro LEDs haveadvantages such as longer service life-time, higher brightness, lessresidual image, and better material stability.

Generally when micro LEDs described in Taiwan Patent No. 201640697A orin the paper “Zhao Jun Liu et al., Monolithic LED Microdisplay on ActiveMatrix Substrate Using Flip-Chip Technology, IEEE Journal of SelectedTopics In Quantum Electronics, pp. 1-5 (2009)” are used to manufacture adisplay module, micro LEDs of different colors must be manufactured indifferent batches respectively and are then attached in batches to acontrol circuit board, then a passivation layer and electrodes areformed through a physical deposition process, and the resultingstructure is packaged to complete a micro LED display module.

However, because of the minimum volume of the micro LEDs, it isdifficult to transfer (pick up and place) and wire bond the micro LEDsduring the process of attaching the micro LEDs of different colors inbatch, and this leads to low product yield, low production efficiencyand high production cost.

SUMMARY OF THE INVENTION

The present invention provides a micro LED display module and amanufacturing method thereof, in which a plurality of micro LEDs isproduced in an array form and disposed on a driver chip block so thateach of the micro LED pixels is driven individually by pixel electrodeson the driver chip block; and a light transmissive conductive layer isused as a common electrode of the plurality of pixels. In this way, eachof the micro LEDs can be addressed by the driver chip so as to emitlight separately. Besides, the plurality of micro LEDs which areproduced in an array form and can be transferred easily in themanufacturing process.

Additionally, for the display of full-color images by the micro LEDdisplay module, a RGB (Red, Green, Blue) color layer may be furtherdisposed, for example, a RGB color filter or quantum dots sprayed layermay be disposed. Therefore, a micro LED display module of highresolution can be produced; and the problem of low product yield thatwould otherwise be caused during the process of transferring the microLEDs can be mitigated.

To achieve the aforesaid objectives, the present invention provides amanufacturing method of a micro light emitting diode (LED) displaymodule, the method comprising the following steps: preparing a LED waferand a driver circuit wafer, wherein a portion of the LED wafer isdefined as a LED block, a chip size portion of the driver circuit waferis defined as a driver chip block, the LED block has a firstsemiconductor layer, a light emitting layer and a second semiconductorlayer, the light emitting layer is disposed between the firstsemiconductor layer and the second semiconductor layer, the firstsemiconductor layer connects with a substrate, and one of the firstsemiconductor layer and the second semiconductor layer is a N-typesemiconductor layer and the other is a P-type semiconductor layer;bonding the LED block and the driver chip block to each other, whereinthe second semiconductor layer is electrically connected to a pluralityof pixel electrodes of the driver chip block; removing the substrate;etching the LED block to form a plurality of trenches arrangedcrisscrossingly, wherein the trenches define a plurality of micro LEDpixels arranged in an array, and each of the micro LED pixelscorresponds to one of the pixel electrodes; disposing a lighttransmissive conductive layer on the first semiconductor layer, whereinthe light transmissive conductive layer has a common electrodecorresponding to the micro LED pixels; and disposing a color layer onthe light transmissive conductive layer, wherein the color layer is aRGB color layer.

To achieve the aforesaid objectives, the present invention provides amicro LED display module, which comprises: a driver chip block, having aplurality of pixel electrodes; a LED block, being disposed on the driverchip block and comprising two semiconductor layers and a plurality oftrenches, wherein the light emitting layer is disposed between the twosemiconductor layers, one of the two semiconductor layers iselectrically connected to the pixel electrodes and the other isconnected to a light transmissive conductive layer, the LED block islocated between the light transmissive conductive layer and the driverchip block, the trenches define a plurality of micro LED pixels arrangedin an array, each of the trenches at least penetrates through the lightemitting layer and the semiconductor layer that is electricallyconnected to the pixel electrodes, each of the micro LED pixelscorresponds to one of the pixel electrodes, one of the two semiconductorlayers is a N-type semiconductor layer and the other is a P-typesemiconductor layer; a circuit board electrically connected to thedriver chip block, wherein the driver chip block is located between theLED block and the circuit board; and a color layer, being disposed onthe light transmissive conductive layer, wherein the light transmissiveconductive layer is located between the color layer and the LED block,and the color layer is a RGB color layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a LED wafer according to the presentinvention;

FIG. 2 is a schematic view of a LED block according to the presentinvention;

FIG. 3 is a schematic cross-sectional view of a LED block according tothe present invention;

FIG. 4 is a schematic view of a driver circuit wafer according to thepresent invention;

FIG. 5 is a schematic view of a driver chip block according to thepresent invention;

FIGS. 6A to 61 are schematic views of a first embodiment and otheralternative embodiments according to the present invention;

FIGS. 7A to 7L are schematic views of a second embodiment and otheralternative embodiments according to the present invention;

FIGS. 8A to 8G are schematic views of a third embodiment and otheralternative embodiments according to the present invention;

FIGS. 9A to 9H are schematic views of a fourth embodiment and otheralternative embodiments according to the present invention;

FIGS. 10 to 11 are schematic views illustrating a step of disposing acolor layer according to the present invention; and

FIG. 10A is a partially enlarged view of a color filter according to thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Hereinbelow, possible implementations of the present invention will bedescribed with reference to embodiments thereof. However, it shall befirstly appreciated that, this is not intended to limit the scope of thepresent invention.

Please refer to FIG. 1 to FIG. 5, which show a LED wafer 110, a LEDblock 111, a driver circuit wafer 120 and a driver chip block 121 to beinitially prepared in the manufacturing process of the presentinvention. For convenience of describing the embodiments of the presentinvention, unless otherwise stated in this specification, the LED block111 may represent a portion of the LED wafer 110 which is stillintegrally connected with other portions of the LED wafer 110 or may bea portion that has already been diced from the LED wafer 110; and thedriver chip block 121 may represent a portion of the driver circuitwafer 120 which is still integrally connected with other portions of thedriver circuit wafer 120 or may be a driver chip that has already beendiced from the driver circuit wafer 120. Each driver chip block 121 hasa plurality of pixel electrodes 122 thereon, and each of the pixelelectrodes 122 can independently drive a micro LED pixel.

That is, the time point at which the LED block 111 is diced from the LEDwafer 110 and/or the driver chip block 121 is diced from the drivercircuit wafer 120 may be any time point between the step of preparingthe LED wafer and the driver circuit wafer and the step of electricallyconnecting the driver chip block with a circuit board.

In the present invention, when the LED wafer 110 and the driver circuitwafer 120 are prepared, some blank regions (e.g., regions where nosemiconductor layer, light emitting layer, and pixel electrodes areprovided) may be reserved for subsequently disposing electrode padsthereon or for performing dicing procedures thereon.

In additional, some lines shown in the drawings are only imaginary linesused in subsequent processes such as etching or dicing processes, andthere may be no such lines in practice.

Please refer to FIG. 6C, FIG. 6D, FIG. 6E, FIG. 6G and FIG. 6H, whichshow a first embodiment of the present invention. The manufacturingmethod of a micro LED display module 600 of this embodiment comprisesthe following steps.

Initially, a LED wafer 610 and a driver circuit wafer 620 are prepared.A portion of the LED wafer 610 is defined as a LED block 611, and a chipsize portion of the driver circuit wafer 620 is defined as a driver chipblock 621. The LED block 611 has a first semiconductor layer, a lightemitting layer 616 and a second semiconductor layer. The light emittinglayer 616 is disposed between the first semiconductor layer and thesecond semiconductor layer. The first semiconductor layer connects witha substrate 612. More specifically, one of the first semiconductor layerand the second semiconductor layer is a N-type semiconductor layer andthe other is a P-type semiconductor layer; and in this embodiment, thefirst semiconductor layer is a N-type semiconductor layer 613 and thesecond semiconductor layer is a P-type semiconductor layer 617. TheN-type semiconductor layer 613 comprises a N-type doped layer 614 and aN-type buffer layer 615, and the N-type doped layer 614 is locatedbetween the N-type buffer layer 615 and the light emitting layer 616.The P-type semiconductor layer 617 further comprises a P-type dopedlayer 618 and a P-type buffer layer 619, and the P-type doped layer 618is located between the P-type buffer layer 619 and the light emittinglayer 616. In some embodiments of the present invention, there may notbe the N-type or P-type buffer layer. Further speaking, the driver chipblock 621 has a layer of integrated circuit (IC) and a plurality ofpixel electrodes (on IC layer), wherein each of the pixel electrodes canbe independently driven. The N-type doped layer 614 is a negative-polesemiconductor layer that is rich in electrons, and the P-type dopedlayer 618 is a positive-pole semiconductor layer that is rich in holes.The N-type buffer layer 615 is a transition layer between the N-typedoped layer 614 and outside materials. The P-type buffer layer 619 is atransition layer between the P-type doped layers 618 and outsidematerials.

Referring next to FIG. 6C and FIG. 6D, the LED block 611 and the driverchip block 621 are bonded to each other so that the P-type semiconductorlayer 617 is electrically connected to a plurality of pixel electrodesof the driver chip block 621. Preferably, to prevent influence onproperties of the material, the LED block 611 and the driver chip block621 are bonded by a low-temperature hybrid connection technology at atemperature lower than 200° C. to adhere the LED block 611 and the pixelelectrodes of the driver chip block 621 together. It can be understoodthat, electrode pads may be additionally disposed to facilitate adhesionor electrical conduction. It shall be appreciated that, in thisembodiment of the present invention, the LED block 611 and the driverchip block 621 have already been diced from the LED wafer and the drivercircuit wafer respectively before the bonding step is performed. Furtherin another embodiment as shown in FIG. 6A, the whole LED wafer 610 maybe bonded to the driver circuit wafer 620; or as shown in FIG. 6B, theLED block 611 may be diced from the LED wafer in advance and then bondedto the driver circuit wafer 620. Referring next to FIG. 6E, thesubstrate 612 is removed and the LED block 611 is etched to form aplurality of trenches 631 arranged crisscrossingly. The trenches 631define a plurality of micro LED pixels 630 arranged in an array (i.e., amicro LED array), and each of the micro LED pixels 630 corresponds toone of the pixel electrodes. In this way, each of the micro LED pixels630 can be powered separately by a corresponding pixel electrode. Itshall be appreciated that, the size of each of the micro LED pixels 630is usually at the micrometer scale.

Referring next to FIG. 6F, non-conductive glue 632 is filled into thetrenches 631 to improve the structural strength between the micro LEDpixels 630. In other embodiments of the present invention, this step maybe omitted.

Referring next to FIG. 6G, a light transmissive conductive layer 640 isdisposed on the N-type semiconductor layer 631. More specifically, thelight transmissive conductive layer 640 comprises a glass layer coatedwith an ITO conductive film, and the ITO conductive film is electricallyconnected with each of the micro LED pixels 630, so that the ITOconductive film is the common electrode corresponding to the micro LEDpixels 630. Moreover, the light transmissive conductive layer 640 iselectrically connected to the driver chip block 621 via a conductiveglue 650 (or other conductors). With a potential difference between theITO conductive film and the pixel electrodes, each of the micro LEDpixels 630 can be controlled to light up.

Referring next to FIG. 6H, the driver chip block 621 is electricallyconnected to a circuit board 660 (a printed circuit board (PCB) or aflexible circuit board). Further speaking, the driver chip block 621 isdisposed on the circuit board 660 and is electrically connected to thecircuit board 660 through wire bonding. It shall be appreciated that,when this step is performed, the driver chip block 621 and the LED block611 have already been diced from the driver circuit wafer and the LEDwafer respectively (i.e., have been in the form of an independent LEDpixel array and an independent driver chip respectively). In anotherembodiment as shown in FIG. 6I, the conductive glue 650 may not connectthe driver chip block 621, but connect the light transmissive conductivelayer 640 and the circuit board 660. In some embodiments of the presentinvention, the conductive glue may not be provided, and instead, the ITOconductive film is electrically connected to other external powersources as long as there is a potential difference between the ITOconductive film and the pixel electrodes to allow each micro LED pixelto light up.

Through the aforesaid steps, the micro LED display module 600 as shownin FIG. 6H can be produced. The micro LED display module comprises thedriver chip block 621, the LED block 611, the light transmissiveconductive layer 640, and the circuit board 660. The driver chip block621 has a plurality of pixel electrodes. The LED block 611 is disposedon the driver chip block 621. The LED block 611 has the firstsemiconductor layer, the light emitting layer 616, the secondsemiconductor layer and a plurality of trenches 631. The light emittinglayer 616 is located between the first semiconductor layer and thesecond semiconductor layer. The second semiconductor layer iselectrically connected to the pixel electrodes. The trenches 631 definethe plurality of micro LED pixels 630 arranged in an array form. Each ofthe trenches 631 penetrates through the first semiconductor layer, thesecond semiconductor layer and the light emitting layer 616. Each of themicro LED pixels 630 corresponds to one of the pixel electrodes. One ofthe first semiconductor layer and the second semiconductor layer is theN-type semiconductor layer 613 and the other is the p-type semiconductorlayer 617. Each of the trenches 631 is filled with the non-conductiveglue 632 therein.

The light transmissive conductive layer 640 is disposed on the LED block611 and connected to the first semiconductor layer. The LED block 611 islocated between the light transmissive conductive layer 640 and thedriver chip block 621. The circuit board 660 is electrically connectedto the driver chip block 621, and the driver chip block 621 is locatedbetween the LED block 611 and the circuit board 660. The conductive glue650 is disposed between the light transmissive conductive layer 640 andthe driver chip block 621 to electrically connect the light transmissiveconductive layer 640 and the driver chip block 621. The lighttransmissive conductive layer 640 comprises the glass layer coated withthe ITO conductive film, and the ITO conductive film is electricallyconnected to each of the micro LED pixels 630. In another embodiment asshown in FIG. 6I, the conductive glue 650 may also be disposed betweenthe light transmissive conductive layer 640 and the driver chip block621 to electrically connect the light transmissive conductive layer 640and the driver chip block 621.

Please refer to FIG. 7A, FIG. 7B, FIG. 7E, FIG. 7F, FIG. 7G, FIG. 7H andFIG. 7I, which show a second embodiment of the present invention. Amanufacturing method of a micro LED display module 700 according to thisembodiment comprises the following steps.

Initially, a LED wafer 710 and a driver circuit wafer 720 are prepared.A portion of the LED wafer 710 is defined as a LED block 711, and a chipsize portion of the driver circuit wafer 720 is defined as a driver chipblock 721. The LED block 711 has a first semiconductor layer, a lightemitting layer 716 and a second semiconductor layer. The light emittinglayer 716 is disposed between the first semiconductor layer and thesecond semiconductor layer. The first semiconductor layer connects witha substrate 712. One of the first semiconductor layer and the secondsemiconductor layer is a N-type semiconductor layer and the other is aP-type semiconductor layer. More specifically, the first semiconductorlayer is a N-type semiconductor layer 713 and the second semiconductorlayer is a P-type semiconductor layer 717. The N-type semiconductorlayer 713 comprises a N-type doped layer 714 and a N-type buffer layer715, and the N-type doped layer 714 is located between the N-type bufferlayer 715 and the light emitting layer 716. The P-type semiconductorlayer 717 further comprises a P-type doped layer 718 and a P-type bufferlayer 719, and the P-type doped layer 718 is located between the P-typebuffer layer 719 and the light emitting layer 716. In some embodimentsof the present invention, there may not be the N-type or P-type bufferlayer.

Referring to FIG. 7A, the LED block 711 is etched to form a plurality oftrenches 731 arranged crisscrossingly. The trenches 731 define aplurality of micro LED pixels 730 arranged in an array (i.e., a microLED array), and each of the trenches 731 at least penetrates through theP-type semiconductor layer 717 and the light emitting layer 716. Furtherspeaking, each of the trenches 731 does not penetrate through the N-typesemiconductor layer 713, and the N-type semiconductor layer 713 is acommon electrode corresponding to the micro LED pixels 730. In otherembodiments of the present invention, each of the trenches may penetratethrough the N-type semiconductor layer or penetrate through only theN-type doped layer as long as there is a common electrode for the lighttransmissive conductive layer. It can be understood that, the step ofetching the LED block may etch the whole LED wafer, or etch only the LEDblock 711 that has been diced.

Referring next to FIG. 7B, non-conductive glue 732 is filled into thetrenches 731 to improve the structural strength between the micro LEDpixels 730. In other embodiments of the present invention, this step maybe omitted.

Referring next to FIG. 7E and FIG. 7F, the LED block 711 and the driverchip block 721 are bonded to each other so that the P-type semiconductorlayer 717 is electrically connected to a plurality of pixel electrodesof the driver chip block 721. Preferably, to prevent influence onproperties of the material, the LED block 711 and the driver chip block721 are bonded by a low-temperature hybrid connection technology at atemperature lower than 200° C. Each of the micro LED pixels 730corresponds to one of the pixel electrodes. In this way, each micro LEDpixel 730 can be independently driven by a corresponding pixelelectrode. It shall be appreciated that, the size of each micro LEDpixels 730 is usually at the micrometer scale. In this embodiment of thepresent invention, the LED block 711 and the driver chip block 721 havealready been diced from the LED wafer 710 and the driver circuit wafer720 respectively before the bonding step is performed. It can beunderstood that, in another embodiment as shown in FIG. 7C, the wholeLED wafer 710 may be bonded to the driver circuit wafer 720 and a dicingprocess is performed subsequently; or as shown in FIG. 7D, the LED block711 may be diced from the LED wafer 710 in advance and then bonded to acorresponding position on the driver circuit wafer 720, and a dicingprocess is performed subsequently.

Referring next to FIG. 7G, the substrate is removed.

Referring next to FIG. 7H, a light transmissive conductive layer 740 isdisposed on the N-type semiconductor layer 713, wherein the lighttransmissive conductive layer 740 has a common electrode correspondingto the micro LED pixels 730. Further speaking, the light transmissiveconductive layer 740 comprises a glass layer coated with an ITOconductive film, and the ITO conductive film is electrically connectedwith each of the micro LED pixels 730. So that the ITO conductive filmis the common electrode corresponding to the micro LED pixels 730.Moreover, the light transmissive conductive layer 740 is electricallyconnected to the driver chip block 721 via a conductive glue 750 sothat, with a potential difference between the ITO conductive film andthe pixel electrodes, each of the micro LED pixels 730 can be controlledto light up. In another embodiment as shown in FIG. 7K and FIG. 7L, thelight transmissive conductive layer 740 may also be an ITO conductivelayer formed through physical sputtering instead of having a glasslayer.

Referring next to FIG. 7I, the driver chip block 721 is electricallyconnected to a circuit board 760. It shall be appreciated that, whenthis step is performed, the driver chip block 721 and the LED block 711have already been diced from the driver circuit wafer 720 and the LEDwafer 710 respectively (i.e., have been in the form of an independentLED pixel array and an independent driver chip respectively). In anotherembodiment as shown in FIG. 7J, the conductive glue 750 may not connectthe driver chip block 721, but connect the light transmissive conductivelayer 740 and the circuit board 760. In some embodiments of the presentinvention, the conductive glue may not be provided, and instead, the ITOconductive film is electrically connected to other external powersources as long as there is a potential difference between the ITOconductive film and the pixel electrodes to allow each micro LED pixelto light up.

Through the aforesaid steps, a micro LED display module 700 as shown inFIG. 7I can be produced in this embodiment of the present invention. Themicro LED display module 700 comprises the driver chip block 721, theLED block 711, the light transmissive conductive layer 740, and thecircuit board 760. The driver chip block 721 has a plurality of pixelelectrodes. The LED block 711 is disposed on the driver chip block 721.The LED block 711 has the first semiconductor layer, the light emittinglayer 716, the second semiconductor layer and a plurality of trenches731. The light emitting layer 716 is located between the firstsemiconductor layer and the second semiconductor layer. The secondsemiconductor layer is electrically connected to the pixel electrodes.The trenches 731 define the plurality of micro LED pixels 730 arrangedin an array form. Each of the trenches 731 penetrates through the secondsemiconductor layer and the light emitting layer 716. Each of the microLED pixels 730 corresponds to one of the pixel electrodes. One of thefirst semiconductor layer and the second semiconductor layer is theN-type semiconductor layer 713 and the other is the p-type semiconductorlayer 717. Each of the trenches 731 is filled with the non-conductiveglue 732 therein.

The light transmissive conductive layer 740 is disposed on the LED block711 and connected to the first semiconductor layer. The LED block 711 islocated between the light transmissive conductive layer 740 and thedriver chip block 721. The circuit board 760 is electrically connectedto the driver chip block 721, and the driver chip block 721 is locatedbetween the LED block 711 and the circuit board 760. The conductive glue750 is disposed between the light transmissive conductive layer 740 andthe driver chip block 721 to electrically connect the light transmissiveconductive layer 740 and the driver chip block 721 respectively. Thelight transmissive conductive layer 740 comprises a glass layer coatedwith an ITO conductive film, and the ITO conductive film is electricallyconnected to each of the micro LED pixels 730 (of course, the lighttransmissive conductive layer 740 may also have only the ITO conductivelayer but not have the glass layer as shown in FIG. 7L). In anotherembodiment as shown in FIG. 7J, the conductive glue 750 may also bedisposed between the light transmissive conductive layer 740 and thedriver chip block 721 to electrically connect the light transmissiveconductive layer 740 and the driver chip block 721 respectively.

Please refer to FIG. 8A, FIG. 8B, FIG. 8C, FIG. 8D, FIG. 8E and FIG. 8F,which show a third embodiment of the present invention. A manufacturingmethod of a micro LED display module 800 according to this embodimentcomprises the following steps.

Initially, a LED wafer 810 and a driver circuit wafer are prepared. Aportion of the LED wafer 810 is defined as a LED block 811, and a chipsize portion of the driver circuit wafer 820 is defined as a driver chipblock 821. The LED block 811 has a first semiconductor layer, a lightemitting layer 816 and a second semiconductor layer. The light emittinglayer 816 is disposed between the first semiconductor layer and thesecond semiconductor layer. The first semiconductor layer connects witha substrate 812. One of the first semiconductor layer and the secondsemiconductor layer is a N-type semiconductor layer and the other is aP-type semiconductor layer. More specifically, the first semiconductorlayer is a N-type semiconductor layer 813 and the second semiconductorlayer is a P-type semiconductor layer 817. The N-type semiconductorlayer 813 comprises a N-type doped layer 814 and a N-type buffer layer815, and the N-type doped layer 814 is located between the N-type bufferlayer 815 and the light emitting layer 816. The P-type semiconductorlayer 817 further comprises a P-type doped layer 818 and a P-type bufferlayer 819, and the P-type doped layer 818 is located between the P-typebuffer layer 819 and the light emitting layer 816. In some embodimentsof the present invention, there may not be the N-type or P-type bufferlayer.

A light transmissive conductive layer 840 is disposed on the P-typesemiconductor layer 817 of the LED block 811. Further speaking, thelight transmissive conductive layer 840 comprises a glass layer coatedwith an ITO conductive film, and the ITO conductive film is electricallyconnected with the P-type semiconductor layer 817. In this embodiment ofthe present invention, as shown in FIG. 8A, this step is actually tobond the LED wafer 810 and the light transmissive conductive layer 840to each other, and the light transmissive conductive layer 840 is an ITOglass wafer. After the step is finished, the LED block 811 is diced fromthe LED wafer 810, as shown in FIG. 8B. In other embodiments of thepresent invention, the LED block 811 may be diced from the LED wafer 810in another subsequent step.

Next, as described in FIG. 8C, the substrate 812 is removed, and the LEDblock 811 is etched to form a plurality of trenches 831 arrangedcrisscrossingly. The trenches 831 define a plurality of micro LED pixels830 arranged in an array, and each of the trenches 831 at leastpenetrates through the N-type semiconductor layer 813 and the lightemitting layer 816. In this embodiment of the present invention, each ofthe trenches 831 does not penetrate through the P-type semiconductorlayer 817, and the ITO conductive film and the P-type semiconductorlayer 817 act as a common electrode corresponding to the micro LEDpixels 830. In other embodiments of the present invention, each of thetrenches may penetrate through the P-type semiconductor layer orpenetrate through only the P-type doped layer, so that all of the microLED pixels can move in an array instead of moving individually. It canbe understood that, the whole LED wafer may be etched in the step ofetching the LED block.

Referring next to FIG. 8D, non-conductive glue 832 is filled into thetrenches 831 to improve the structural strength between the micro LEDpixels 830. In other embodiments of the present invention, this step maybe omitted.

Referring next to FIG. 8E, the LED block 811 and the driver chip block821 are bonded to each other so that the N-type semiconductor layer 813is electrically connected to a plurality of pixel electrodes of thedriver chip block 821. Preferably, to prevent influence on properties ofthe material, the LED block 811 and the driver chip block 821 are bondedby a low-temperature hybrid connection technology at a temperature lowerthan 200° C. Each of the micro LED pixels 830 corresponds to one of thepixel electrodes. In this way, each of the micro LED pixels 830 can beindependently driven by the corresponding pixel electrode. It shall beappreciated that, the size of each of the micro LED pixels 830 isusually at the micrometer scale. In this embodiment of the presentinvention, the LED block 811 and the driver chip block 821 have alreadybeen diced from the LED wafer and the driver circuit wafer respectivelybefore the bonding step is performed. It can be understood that, inother embodiments of the present invention, it may be that the whole LEDwafer is bonded to the driver circuit wafer; or the LED block is dicedfrom the LED wafer in advance and then bonded to a correspondingposition on the driver circuit wafer, then the driver circuit wafer isdiced in another subsequent step.

Referring next to FIG. 8F, the driver chip block 821 is electricallyconnected to a circuit board 860. It shall be appreciated that, whenthis step is performed, the driver chip block 821 and the LED block 811have already been diced from the driver circuit wafer and the LED waferrespectively (i.e., have been in the form of an independent LED pixelarray and an independent driver chip respectively). In this embodimentof the present invention, the light transmissive conductive layer 840 iselectrically connected to the driver chip block 821 via a conductiveglue 850 so that, with a potential difference between the ITO conductivefilm and the pixel electrodes, each of the micro LED pixels 830 can becontrolled to light up. In other embodiments as shown in FIG. 8G, theconductive glue 850 may electrically connect the light transmissiveconductive layer 840 and the circuit board 860 but not connect thedriver chip block 821. In some embodiments of the present invention, theconductive glue may not be disposed and, instead, the ITO conductivefilm is electrically connected to other external power sources as longas there is a potential difference between the ITO conductive film andthe pixel electrodes to allow each micro LED pixel to light up.

Through the aforesaid steps, a micro LED display module 800 as shown inFIG. 8F can be produced in this embodiment of the present invention. Themicro LED display module comprises the driver chip block 821, the LEDblock 811, the light transmissive conductive layer 840, and the circuitboard 860. The driver chip block 821 has the plurality of pixelelectrodes. The LED block 811 is disposed on the driver chip block 821.The LED block 811 has the first semiconductor layer, the light emittinglayer 816, the second semiconductor layer and the plurality of trenches831. The light emitting layer 816 is located between the firstsemiconductor layer and the second semiconductor layer. The secondsemiconductor layer is electrically connected to the pixel electrodes.The trenches 831 define the plurality of micro LED pixels 830 arrangedin an array form. Each of the trenches 831 penetrates through the secondsemiconductor layer and the light emitting layer 816. Each of the microLED pixels 830 corresponds to one of the pixel electrodes. One of thefirst semiconductor layer and the second semiconductor layer is theN-type semiconductor layer 813 and the other is the P-type semiconductorlayer 817. Each of the trenches 831 is filled with the non-conductiveglue 832 therein.

The light transmissive conductive layer 840 is disposed on the LED block811 and connected to the first semiconductor layer. The LED block 811 islocated between the light transmissive conductive layer 840 and thedriver chip block 821. The circuit board 860 is electrically connectedto the driver chip block 821, and the driver chip block 821 is locatedbetween the LED block 811 and the circuit board 860. A conductive glue850 is disposed between the light transmissive conductive layer 840 andthe driver chip block 821 to electrically connect the light transmissiveconductive layer 840 and the driver chip block 821 respectively. Thelight transmissive conductive layer 840 comprises a glass layer coatedwith the ITO conductive film, and the ITO conductive film iselectrically connected to each of the micro LED pixels 830. In anotherembodiment as shown in FIG. 8G, the conductive glue 850 may also bedisposed between the light transmissive conductive layer 840 and thedriver chip block 821 to electrically connect the light transmissiveconductive layer 840 and the driver chip block 821 respectively.

Please refer to FIG. 9A, FIG. 9B, FIG. 9E, FIG. 9F and FIG. 9G, whichshow a fourth embodiment of the present invention. A manufacturingmethod of a micro LED display module having a light transmissivesubstrate according to this embodiment comprises the following steps.

Initially, a LED wafer 910 and a driver circuit wafer 920 are prepared.A portion of the LED wafer 910 is defined as a LED block 911, and a chipsize portion of the driver circuit wafer 920 is defined as a driver chipblock 921. The LED block 911 has a first semiconductor layer, a lightemitting layer 916 and a second semiconductor layer. The light emittinglayer 916 is disposed between the first semiconductor layer and thesecond semiconductor layer. The first semiconductor layer connects witha light transmissive substrate 912. One of the first semiconductor layerand the second semiconductor layer is a N-type semiconductor layer andthe other is a P-type semiconductor layer. More specifically, the firstsemiconductor layer is a N-type semiconductor layer 913 and the secondsemiconductor layer is a P-type semiconductor layer 917. The N-typesemiconductor layer 913 comprises a N-type doped layer 914 and a N-typebuffer layer 915, and the N-type doped layer 914 is located between theN-type buffer layer 915 and the light emitting layer 916. The P-typesemiconductor layer 917 further comprises a P-type doped layer 918 and aP-type buffer layer 919, and the P-type doped layer 918 is locatedbetween the P-type buffer layer 919 and the light emitting layer 916. Insome embodiments of the present invention, there may not be the N-typeor P-type buffer layer. The light transmissive substrate has good lighttransmissivity with respect to the visible band, e.g., may be a sapphiresubstrate.

Referring to FIG. 9A, the LED block 911 is etched to form a plurality oftrenches 931 arranged crisscrossingly. The trenches 931 define aplurality of micro LED pixels 930 arranged in an array, and each of thetrenches 931 penetrates through the P-type semiconductor layer 917 andthe light emitting layer 916. Further speaking, each of the trenches 931does not penetrate through the N-type semiconductor layer 913, and theN-type semiconductor layer 913 has a common electrode corresponding tothe micro LED pixels 930.

In other embodiments of the present invention, each of the trenches mayalso penetrate through the N-type semiconductor layer as long as atleast a part of the N-type semiconductor layer can act as a commonelectrode. It can be understood that, the step of etching the LED blockmay etch the whole LED wafer, or etch only the LED block 911 that hasbeen diced. The N-type semiconductor layer 913 has a common electrodecorresponding to the micro LED pixels 930, and the common electrode hasa protrusion 970 that protrudes in the horizontal direction. In thisembodiment of the present invention, the N-type buffer layer 915 has theprotrusion 970, which is generated during the step of etching the LEDblock, and the N-type buffer layer 915 acts as the common electrode ofthe micro LED pixels.

Referring next to FIG. 9B, a non-conductive glue 932 is filled into thetrenches 931 to improve the structural strength between the micro LEDpixels 930. In other embodiments of the present invention, this step maybe omitted.

Referring next to FIG. 9E and FIG. 9F, the LED block 911 and the driverchip block 921 are bonded to each other so that the P-type semiconductorlayer 917 is electrically connected to a plurality of pixel electrodesof the driver chip block 921. Preferably, to prevent influence onproperties of the material, the LED block 911 and the driver chip block921 are bonded by a low-temperature hybrid connection technology at atemperature lower than 200° C. Each of the micro LED pixels 930corresponds to one of the pixel electrodes. In this way, each micro LEDpixel 930 can be independently powered by the corresponding pixelelectrode. It shall be appreciated that, the size of each micro LEDpixels 930 is usually at the micrometer scale. In this embodiment of thepresent invention, the LED block 911 and the driver chip block 921 havealready been diced from the LED wafer and the driver circuit waferrespectively before the bonding step is performed. It can be understoodthat, in another embodiment as shown in FIG. 9C, the whole LED wafer 910is bonded to the driver circuit wafer 920; or as shown in FIG. 9D, theLED block 911 is diced from the LED wafer 910 first and then bonded to acorresponding position on the driver circuit wafer 920, and a dicingprocess is performed subsequently.

Besides, the protrusion 970 is electrically connected to the driver chipblock 921 via a conductive glue 950 so that, with a potential differencebetween the N-type buffer layer 915 and the pixel electrodes, each ofthe micro LED pixels 930 can be controlled to light up. It shall beappreciated that, this embodiment does not need to remove the lighttransmissive substrate 912.

Referring next to FIG. 9G, the driver chip block 921 is electricallyconnected to a circuit board 960. It shall be appreciated that, whenthis step is performed, the driver chip block 921 and the LED block 911have already been diced from the driver circuit wafer 920 and the LEDwafer 910 respectively (i.e., have been in the form of an independentLED pixel array and an independent driver chip respectively). In anotherembodiment as shown in FIG. 9H, the conductive glue 950 may not connectthe driver chip block 921, but connect the protrusion 970 and thecircuit board 960. In some embodiments of the present invention, theconductive glue 950 may not be provided, and instead, the ITO conductivefilm is electrically connected to other external power sources as longas there is a potential difference between the ITO conductive film andthe pixel electrodes to allow each micro LED pixel 930 to light up.

Through the aforesaid steps, a micro LED display module having a lighttransmissive substrate as shown in FIG. 9G can be produced in thisembodiment of the present invention. The micro LED display modulecomprises the driver chip block 921, the LED block 911, and the circuitboard 960. The driver chip block 921 has a plurality of pixelelectrodes. The LED block 911 is disposed on the driver chip block 921.The LED block 911 has the first semiconductor layer, the light emittinglayer 916, the second semiconductor layer and the plurality of trenches931. The light emitting layer 916 is located between the firstsemiconductor layer and the second semiconductor layer. The secondsemiconductor layer is electrically connected to the pixel electrodes.The trenches 931 define the plurality of micro LED pixels 930 arrangedin an array form. Each of the trenches 931 penetrates through the secondsemiconductor layer and the light emitting layer 916. Each of the microLED pixels 930 corresponds to one of the pixel electrodes. Each of thetrenches 931 is filled with the non-conductive glue 932 therein. Thefirst semiconductor layer has the protrusion 970 that protrudes in thehorizontal direction. The first semiconductor layer is connected to thelight transmissive substrate 912 and located between the lighttransmissive substrate 912 and the light emitting layer 916.

The circuit board 960 is electrically connected to the driver chip block921, and the driver chip block 921 is located between the LED block 911and the circuit board 960. A conductive glue 950 is disposed between theprotrusion 970 and the driver chip block 921 to electrically connect theprotrusion 970 and the driver chip block 921 respectively. In anotherembodiment as shown in FIG. 9H, the conductive glue 950 may also bedisposed between the protrusion 970 and the circuit board 960 toelectrically connect the protrusion 970 and the circuit board 960respectively.

Referring to FIG. 10, to have each of the micro LED display modules ofall the aforesaid embodiments emit light of different colors, a colorlayer 170 (a RGB color layer) may be additionally disposed to emit lightof three colors from the micro LED display module. Further speaking, thecolor layer 170 is formed by spraying a corresponding RGB quantum dot oneach of the micro LED pixels so that the quantum dots are excited by themicro LED pixels to emit light of the three colors. Further speaking,the color layer 170 has a plurality of red, blue and green pixel regions171, 172, 173, each of which corresponds to one of the micro LED pixels,and the color layer 170 has a plurality of full-color display dots(units capable of displaying light of the three colors). Each of thefull-color dots has at least three-pixel regions 171, 172, 173 adjacentto each other, at least including one red pixel region 171, one bluepixel region 172 and one green pixel region 173. Preferably, to satisfyrequirements of the manufacturing process, one full-color display dotmay include four-pixel regions adjacent to each other (e.g., one redpixel region 171, one blue pixel region 172 and two green pixel regions173 as shown in FIG. 10A) so that the full-color display dots arearranged regularly. In other embodiments as shown in FIG. 11, the colorlayer 180 may also be a RGB color filter.

In the various embodiments of the present invention, novel structuresand methods have been described for to a micro LED display module and amanufacturing method thereof. The various embodiments of the structuresand methods of this invention that are described above are illustrativeonly of the principles of this invention and are not intended to limitthe scope of the invention to the particular embodiment described. Thus,the invention is limited only by the following claims.

What is claimed is:
 1. A manufacturing method of micro light emitting diode (LED) display module, the manufacturing method comprising the following steps: preparing a LED wafer and a driver circuit wafer, wherein a portion of the LED wafer is defined as a LED block, a chip size portion of the driver circuit wafer is defined as a driver chip block, the LED block has a first semiconductor layer, a light emitting layer and a second semiconductor layer, the light emitting layer is disposed between the first semiconductor layer and the second semiconductor layer, the first semiconductor layer connects with a substrate, and one of the first semiconductor layer and the second semiconductor layer is a N-type semiconductor layer and the other is a P-type semiconductor layer; bonding the LED block and the driver chip block to each other, wherein the second semiconductor layer is electrically connected to a plurality of pixel electrodes of the driver chip block; removing the substrate; etching the LED block to form a plurality of trenches arranged crisscrossingly, wherein the trenches define a plurality of micro LED pixels arranged in an array, and each of the micro LED pixels corresponds to one of the pixel electrodes; disposing a light transmissive conductive layer on the first semiconductor layer, wherein the light transmissive conductive layer has a common electrode corresponding to the micro LED pixels; and disposing a color layer on the light transmissive conductive layer, wherein the color layer is a red, green and blue color layer.
 2. The manufacturing method according to claim 1, wherein the N-type semiconductor layer comprises a N-type doped layer and a N-type buffer layer, and the N-type doped layer is located between the N-type buffer layer and the light emitting layer.
 3. The manufacturing method according to claim 1, wherein the P-type semiconductor layer further comprises a P-type doped layer and a P-type buffer layer, and the P-type doped layer is located between the P-type buffer layer and the light emitting layer.
 4. The manufacturing method according to claim 1, further comprising a step of electrically connecting the driver chip block with a circuit board, wherein the driver chip block is a driver chip diced from the driver circuit wafer.
 5. The manufacturing method according to claim 4, wherein the light transmissive conductive layer is electrically connected with the circuit board via a conductive glue.
 6. The manufacturing method according to claim 1, wherein the light transmissive conductive layer is electrically connected with the driver chip block via a conductive glue.
 7. The manufacturing method according to claim 1, wherein the light transmissive conductive layer comprises a glass layer coated with an ITO conductive film, and the ITO conductive film is electrically connected with the micro LED pixels.
 8. The manufacturing method according to claim 1, wherein the color layer is a color filter.
 9. The manufacturing method according to claim 1, wherein the color layer is formed by spraying quantum dots.
 10. The manufacturing method according to claim 1, further comprising the following step before the step of bonding the LED block and the driver chip block to each other and after the step of preparing the LED wafer: dicing the LED block from the LED wafer; and the step of bonding the LED block and the driver chip block to each other is to bond the LED block and the driver circuit wafer having the driver chip block to each other.
 11. The manufacturing method according to claim 1, further comprising the following step before the step of bonding the LED block and the driver chip block to each other and after the step of preparing the LED wafer and the driver circuit wafer: dicing the LED block and the driver chip block from the LED wafer and the driver circuit wafer respectively.
 12. The manufacturing method according to claim 1, wherein the step of bonding the LED block and the driver chip block to each other is to bond the LED wafer having the LED block and the driver circuit wafer having the driver chip block to each other.
 13. The manufacturing method according to claim 1, further comprising the following step: filling non-conductive glue into the trenches.
 14. A micro LED display module, comprising: a driver chip block, having a plurality of pixel electrodes; a LED block, being disposed on the driver chip block and comprising two semiconductor layers and a plurality of trenches, wherein the light emitting layer is disposed between the two semiconductor layers, one of the two semiconductor layers is electrically connected to the pixel electrodes and the other is connected to a light transmissive conductive layer, the LED block is located between the light transmissive conductive layer and the driver chip block, the trenches define a plurality of micro LED pixels arranged in an array, each of the trenches at least penetrates through the light emitting layer and the semiconductor layer that is electrically connected to the pixel electrodes, each of the micro LED pixels corresponds to one of the pixel electrodes, one of the two semiconductor layers is a N-type semiconductor layer and the other is a P-type semiconductor layer; a circuit board electrically connected to the driver chip block, wherein the driver chip block is located between the LED block and the circuit board; and a color layer, being disposed on the light transmissive conductive layer, wherein the light transmissive conductive layer is located between the color layer and the LED block, and the color layer is a red, green and blue color layer.
 15. The micro LED display module according to claim 14, wherein the N-type semiconductor layer further comprises a N-type doped layer and a N-type buffer layer, the N-type doped layer is located between the N-type buffer layer and the light emitting layer.
 16. The micro LED display module according to claim 14, wherein the P-type semiconductor layer further comprises a P-type doped layer and a P-type buffer layer, and the P-type doped layer is located between the P-type buffer layer and the light emitting layer.
 17. The micro LED display module according to claim 14, wherein a conductive glue is disposed between the light transmissive conductive layer and the circuit board to electrically connect the light transmissive conductive layer and the circuit board respectively.
 18. The micro LED display module according to claim 14, wherein a conductive glue is disposed between the light transmissive conductive layer and the driver chip block to electrically connect the light transmissive conductive layer and the driver chip block respectively.
 19. The micro LED display module according to claim 14, wherein the light transmissive conductive layer comprises a glass layer coated with an ITO conductive film, and the ITO conductive film is electrically connected with the micro LED pixels.
 20. The micro LED display module according to claim 14, wherein the light transmissive conductive layer is an ITO conductive layer.
 21. The micro LED display module according to claim 14, wherein the color layer is a color filter.
 22. The micro LED display module according to claim 14, wherein the color layer is formed by spraying quantum dots.
 23. The micro LED display module according to claim 14, wherein non-conductive glue is filled in each of the trenches.
 24. The micro LED display module according to claim 14, wherein the semiconductor layer connected to the light transmissive conductive layer is not penetrated through by each of the trenches.
 25. The micro LED display module according to claim 14, wherein each of the trenches penetrates through the semiconductor layer connected to the light transmissive conductive layer. 